Decorative metal panel sheet



Feb' 4, 1941 c. EA'rcHELLx-:R 2,230,823

' DECORATIVE METAL PANEL SHEET Filed Jan. 27, 1937 E ay ,4 7" TQANEYPatented Feb. 4, 1941 UNITED STATES PATENT OFFICE DECORATIVE METAL PANELSHEET Application January 27, 1937, Serial No. 122,572

2 Claims.

My invention relates to. a novel decorative y sheathing panel having ahard, stone-like core or backing formed from initially plastic materialand which is surfaced upon one or both sides with thin gauge metalsheets having ornamental designs embossed or impressed therein whichextend into the core or backing. 'Ihe impressed portions may be eithercolored or plain. It also lo relates to the method of fabricating such apanel. One of the objects of my invention is to provide a panel board oflight weight which is reasonably fire resistant and which has an exposedsurface of thin metal bearing impressed decorative effects either plain,or lhaving coloring material inlaid therein. Another object is toprovide a simple, cheap and eflicient method of procedure whereby suchpanels may be fabricated, and particularly whereby theornamental designis simultaneously impressed in both the facing and backing.

My invention, therefore, includes the novel elements and thecombinations thereof described below and illustrated in the accompanyingdrawing,

and also the method of procedure hereinafter.v

described.

In the drawingl Fig. 1 is a plan view of a specimen panel; Fig. 2 is afragmentary cross section of Fig. 1 in 4the plane 2 2, drawn to anenlarged scale and 3a showing a colored design;

Fig. 3 is a fragmentary cross section similar to Fig. 2 but showing aplain, uncolored design;

Fig. 4 is a cross section similar to Figs. 2 and 3 showing a modifledtype of panel having metal on Fig. 5 is a cross section showing anassembly of the elements making up my panel before the design isimpressed therein;

Fig. 6 is a cross section of a panel showing the lelements thereofseparated after the design is impressed; and

Fig. 7 is a cross section of a finished panel.

Referring to the drawing, my panel comprises a facing sheet I which maybe of brass, aluminum, copper, annealed steel or any other metal whichis sufficiently soft and ductile in thin gauge sheets to be deformed ashereinafter described.

e Since the structural stability of the panel is provided principally bythe backing or core element,

su and for the reason that the metal facing must be fairly easilydeformed, the thickness of the metal used in the facing is preferablykept between 0.00 andV 0.018".

While I may employ metals of different colors 5 and of the generalcharacter described above, I

prefer to employ a corrosion-resistant alloy steel because of its highresistance to the attack of various gaseous and liquid media so that theexposed panel surface formed thereby is of a substantially permanentcharacter. Such alloy steels contain chromium, usually in quantities of8% or more and with or without other elements which enhance thecorrosion-resisting characteristics of the composition; one of the mostWidely` used alloy steels being commonly known as 18 and 5 8, and whichcontains 18% of chromium and 8% of nickel. These steels generally may becold rolled to very thin gauges, and sheets or strips so produced have ahighly lustrous surface finish. While such alloys generally work hardenin the rolling process, they may be rendered soft and easy to work bywellknown annealing processes without destroying the lustrous finish.For use in my panel it is desirable to have the metal in a 15 softannealed condition.

The backing for my product comprises largely fibrous material and ahydraulic cement with which is intermixed minor quantities of bentonite.As a hydraulic cement, I prefer to useeither 2 A or both Portland cementand calcined magnesite.

A composition of this character when combined with a water-miscibleasphalt dispersion in quantities hereinafter pointed out is particularlysuited for use in molding my backing because of its very unusualproperties. A typical formula, without 25 the asphalt, is as follows:

Short asbestos fibers (waste pounds 200 fibers) Calclned magnesite (200mesh) do 30 Bentonlte (200 mesh) do 12 Water to plasticize, aboutgallons-- 20 Another typical formula, without the asphalt dispersion, isas follows:

Grams 35 Cellulose (waste pulp ber) 750 Portland cement '150 Magnesite300 Bentonite .400 Diatomaceous earth 300 40 Wasteasbestos C fibers 400craling even when heated to tempe atures of the order of i300 F. andplunged into water.

The quantities of asbestos fiber and calcined magnesite may be varied tosome considerable degree depending upon the character cf the productdesired. The bentonite is an important essential ingredient but also maybe varied somewhat although the quantity, by weight, will o I generallybe well under of the weight of the total solids and preferably less than5% thereof. Ihe calcined magnesite may be replaced in whole or in partby Portland cement.

In forming my product I prefer to proceed as follows, and in connectionwith/the description it will be assumed that the facing I of the panelis to be formed of a thin gauge sheet of corrosion-resistant alloysteel.

A suitable backing paper 2, for example, a 12- pound high rag-content,asphalt-saturated, sheathing felt, is first applied to the metal surfaceby means of a film of hot 'asphalt 3 between the metal and the paper.Such application may be effected upon the usual coating machinesappropriately modified for the purpose. The metal facing with the paperbacking thereon is then cut to approximately the desired size of thefinished panels.

The backing 4 or the core element 5 is then formed by molding or rollingthe plastic material aforesaid into sheets of the approximate (somewhatgreater) thickness desired in the iinished product.

In order to secure a strong bond between the backing or core element andthe paper-backed metal facing sheets I incorporate in the plastic'composition aforesaid a water miscibie asphalt dispersion preferably insuch quantities as to provide an asphalt content in the composition ofat least 10% to 15% of the total dry weight of the other solidconstituents, and I may also apply a film of asphalt emulsion to thesurface of the paper backing of the metal face. Where the metal facingis to be applied to one side only of the panel, the plastic backingsheet, supported on a steel plate, is placed in an appropriate press andthe paper-backed facing is placed thereon with the paper side resting on.fthe plastic backing. Where the facing sheet of metal is not to beembossed or otherwiseV decorated, a smooth upper press plate is placedthereon and the unit is subjected to a pressure of from 100 to 500 lbs.per square inch. This pressure compresses the plastic backing into ahard, dense mass and effects a very satisfactory bond of the paperbackedfacing element thereto.

Where a decorative impression or` intaglio is to be made in the thinmetal facing sheet, I place thereon a specially prepared steel die orpress plate carrying upon its surface .fthe raised or depressed patterndesired and subject the whole to pressure. In the initial pressingopera- 1 tion the plastic core or backing element contains most of itsplasticizing water and acts as a completely satisfactory cushion for themetal facing sheet above it which is under deformative pressure. Thepressure should be applied gradually until the plastic core or backinghas had much of its water content squeezed therefrom. Thereafter, itoffers sufficient resistance due to its increased density to permit thespecially prepared press plate to effect clear cut impressions 6 as deepas 1% or even M3" in the metal facing.

Owing to the facility with which the metal facing may be deep stampedsimultaneously with its application and bonding to fthe core or backing,the product thus prepared lends itself very readily to a new and novelcolor decoration. After the product has been deep stamped and the coreor backing element has hardened, the depressions in the metal may befilled with any of the suitable resin thermoplastic powders, colored orplain. The product is then introduced into a hot press plate and heatedto about 275 F. for a sufiicient time for the resin powder to melt andsmoothly fill the depressions in themetal facing, as shown at Il in Fig.2. Upon cooling it is simply necessary to subject the sheet product to alight polishing operation -to produce a clean cut inlaid pattern ofgreat beauty.

Instead of proceeding in the manner aforesaid, I may prepare the backingor core element 5 by rolling or molding the plastic material to theapproximate size and thickness of the finished 1 product, as shown at 8in Fig. 5. A film or sheet of thermo-plastic, resinous material 9, suchas a Tego or Vinylite sheet or film, is then placed on the plasticbacking, and the metal facing sheet l0 is laid thereover. (not shown) isthen laid over the facing sheet and the assembly is subjected topressure, as above described, until the design on the die is impressedinto the metal and plastic backing, and the plastic backing iscompressed into a dense mass, as shown in Fig. 7.

It is to be understood that there is no substantial adhesion between thethermo-plastic film and the metal and backing, and that while theelements are formed so that they interfit, they may be readilyseparated, as shown in Fig. 6.

After separation the metal and film are dried and the plastic backing iscured to form a hard, stone-like sheet. Thereafter, the elements arereassembled with the die plate thereon and the assembly is subjected tosufficient pressure and heat in a hot press to melt or soften thethermoplastic film and cause it to adhere both to the facing and backingand thus secure them together. 'I'he pressure should be maintainedduring the cooling and setting of the plastic.

I believe that the successful fabrication of composite panels in themanner described above is largely due to the facility with which myplastic composition lends itself to deformation under thepressure-forming step and which is attributable to the presence of thebentonite there- What I claim is:

'1. A composite panel boardhaving a substantially smooth, flat facingcomprising a sheet of thin stainless steel, a hard, stone-like backingformed principally of fibrous material and hydraulic cement, and alsocontaining bentonite in quantities less than about 10% by weight, and anintermediate layer of paper; said facing,

backing and intermediate layer being adhesively secured together to forma unitary structure; said facing having depressed zones thereof embeddedin ysaid backing and forming an ornamental intaglio'design in the faceof said panel,

and said zones being substantially lled with a thermoplastic material of distinctive color.

2. A composite panel board having a substantially smoothflat facingcomprising a sheet of thin stainless steel, .and a hard, stone-likebacking formed principally of fibrous material and hydraulic cement, andalso containing bentonite in quantities less than Aabout 10% by weight;said facing and backing being adhesively secured together to form aunitary structure; said facing having depressedzones thereof embedded insaid backing and forming an ornamental intaglio design in the face ofsaid panel, and said zones being substantially filled with athermoplastic material of distinctive color.

CLEMENTS BATCHELLER.

A suitable die plate

